Apparatus for forming battery straps and intercell connections

ABSTRACT

Battery plates are assembled into stacks forming positive and negative rows of lugs and the stacks are placed within the cells in a battery case. Molding channels are automatically formed around the positive and negative rows of lugs and molten lead alloy is automatically introduced into the molding channels to cast the straps and intercell connections simultaneously within the battery case.

BACKGROUND OF THE INVENTION

I. Field of the Invention

This disclosure relates to a method and apparatus for automaticallyforming battery straps and intercell connections in a storage battery.

II. Description of the Prior Art

Various techniques exist for forming battery straps and making intercellconnections in a battery. See U.S. Pat. Nos. 3,703,589; 3,652,337;3,579,386; 3,519,489; and 3,514,342.

In Patent No. 3,703,589, alternate plates in each compartment of abattery are electrically interconnected by a crossbar. Conductivebar-like members extend upwardly from the crossbars on opposite sides ofthe compartment partition wall and they are electrically interconnectedat their upper ends by conductive pins which extend through an aperturein the partition wall. The conductive bar-like members are cast in moldsformed in the battery but the crossbars are not. During the castingprocess the conductive bar-like members are connected to the conductivepins. However, a further step is required to seal the connection to thepartition wall by applying pressure through the bar-like members toopposite ends of the pins.

A cast on method of forming straps to battery plates is described inU.S. Pat. No. 3,652,337. A number of alternatively spaced positive andnegative plates with separators therebetween form a cell group whichultimately forms one cell of the finished battery. The lugs of theplates within the cell group form two rows of lugs, a positive row and anegative row. These lugs are cleaned, coated with a lead alloy melt andthen rapidly transferred to a plate strap casting station where the lugsare immersed into a mold filled with molten-strap-forming material.

U.S. Pat. Nos. 3,818,985; 3,815,623; 3,565,162; 2,199,598; and 1,336,767all disclose methods for handling or casting molten metal. Certain ofthese patents disclose methods for continuous or simultaneous pouringfor casting several parts. U.S. Pat. Nos. 3,921,704; 3,371,186, and2,364,615 disclose means of casting molten metal and minimizing theoxidation thereof during the casting process.

More recently a method of molding connectors in electrical accumulatorshas been disclosed in U.S. Pat. No. 3,988,169. The assembly methodaccording to that patent "permits placement of the plates into theirrespective cells prior to their interconnection, and subsequently allowssimultaneous interconnection of plates and forming of intercellconnectors between adjacent cells which are separated by a partitionwall, by flowing molten lead or lead alloy through an aperture in thepartition wall between the cells". The method requires the forming of a"channel adjacent the plates of like polarity in each group of plates".

While U.S. Pat. No. 3,988,169 overcomes some of the disadvantages ofprior art techniques, this patent discloses a method which is dependentupon the hand manipulation of battery plates and molds within thebattery case, with attendant quality control and misalignment problems.Similarly, since polypropylene, a standard battery case material, meltsbelow the temperature of molten lead, the method by which that lead isintroduced adjacent and through the plastic aperture is of particularconcern. See U.S. Pat. No. 3,874,933 which relates to the casting oflead through a plastic aperture. U.S. Pat. No. 3,988,169 does notdescribe means for introducing molten lead into the channels describedtherein nor are the problems relating to the bonding which is obtainedbetween the molten lead and the battery lugs and/or between the lead inadjacent compartments considered by this patent. See U.S. Pat. Nos.3,652,337; 3,238,579; 3,229,339; 3,087,005; 2,799,905; and 2,454,053 fordiscussion of various approaches taken to overcome problems encounteredwhen trying to cast straps to the lugs whith a "cast on" method.Temperature gradients within sections which are successively cast wouldbe expected to result in differential hardening and the formation ofoxide barriers between different portions of the intercell connectionand/or strap. These oxides or dross will substantially increase theinternal resistance of the battery or cell, and may encourage corrosionwhich could, under certain conditions cause premature failure orsparking, the latter of which may have explosive consequences. Use ofstandard ladling techniques to cast the straps and intercell connectionsof the battery of U.S. Pat. No. 3,988,169 also present certain fillcontrol and premature hardening problems since the disclosed moldingchannel is relatively deep and a steady hand would be required to pour athin, accurate stream of molten lead into the channel without splashinglead against the upper portions of the side walls of the mold.

SUMMARY OF THE INVENTION

The present invention describes an improved apparatus for casting thestraps and intercell connections of an electric storage battery. Theapparatus is adapted to efficiently handle standard open-topped batterycases having a plurality of cellular partitions therein. Each of thepartitions has at least one aperture through which the intercellconnections are formed. Stacks of positive and negative plates areinitially placed in each of the cells of the batteries, the stacks ofplates forming rows of protruding positive and negative lugs extendinggenerally toward the top of the battery case.

Automated mold means are provided to automatically align the platestacks within the case and to form tapered molding channels around atleast a portion of the positive and negative rows of lugs in each of thecells. Molten metal alloy is simultaneously introduced into the variousmolding channels from a novel ladle means which minimizes the formationof dross and which forms and introduces a plurality of preselectedaliquots of molten lead into various preselected points along themolding channels. The molten lead flows into the channels and throughthe apertures in the partition thereby forming tapered, homogeneousbattery straps and integral intercell connections while minimizing theamount of lead required to form a finished product.

Accordingly, it is an object of this invention to provide an apparatusfor automatically forming electrically homogeneous battery straps andintercell connections within the battery case.

It is a further object of this invention to cast dross-free straps andintercell connections having tapered configurations.

A further object of this invention is the provision of an apparatus forforming tapered molds within the battery case around the rows ofpositive and negative lugs of the stacks of plates within the battery.

Another object of this invention is the provision of an apparatusadopted to position the battery and align the plates within the batteryprior to and during the introduction of the molding channelstherearound.

Another object of this invention is the provision of an apparatus forforming and delivering preselected aliquots of molten lead to aplurality of lead battery part molds for simultaneous casting in themolds as, for example, the simultaneous casting of battery straps andintercell connections within the battery casing.

These and other objects of my invention will become apparent from thefollowing description with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a cast-in battery making apparatus inaccordance with a preferred embodiment of the present invention;

FIG. 2 is an enlarged cross section of the embodiment of FIG. 1 showingthe ladles and molds in standby positions, taken as indicated by thelines and arrows 2--2 in FIG. 1;

FIG. 3 is a cross section of a portion of the device as illustrated inFIG. 2 wherein the molds have been moved to the closed position;

FIG. 4 is a cross section of a portion of the apparatus illustrated inFIG. 3 taken as indicated by the lines and arrows 3-3 in FIG. 3;

FIG. 5 is a cross section similar to FIG. 3 showing the molds in theclosed position and the ladles in the pouring position;

FIG. 6 is a cross section similar to FIG. 4 showing the lead straps andone intercell connection after pouring;

FIG. 7 is an isometric view of a positive post comb dam;

FIG. 8 is an isometric view of a negative post comb dam;

FIG. 9 is an isometric view of a comb dam;

FIG. 10 is an isometric view of a back dam;

FIG. 11 is an isometric cross-section of a portion of the preferredembodiment ladle of the present invention;

FIG. 12 is a front elevational view of the bisected portion of the ladleillustrated in FIG. 11;

FIG. 13 is a cross-section of the preferred embodiment ladle takenthrough a spout;

FIG. 14, a-d, are diagramatic cross-sections of the preferred embodimentladle in various stages of rotation from the standby position shown inFIG. 14a to the full pouring position as shown in FIG. 14d;

FIG. 15 is a schematic of the preferred embodiment molten lead supplysystem shown in combination with the preferred embodiment ladles of thepresent invention.

DETAILED DESCRIPTION OF THE DRAWINGS

Although specific forms of the invention have been selected forillustration in the drawings, and the following description is drawn inspecific terms for the purpose of describing these forms of theinvention, this description is not intended to limit the scope of theinvention which is defined in the appended claims.

The preferred embodiment apparatus for casting the straps and intercellconnections of a lead acid storage battery is illustrated in thedrawings. Briefly, this apparatus operates as follows: open toppedbattery cases which have been prepunched with apertures for intercellconnections are preloaded with stacks of battery plates and separators.These battery cases are then moved along a work surface to a processingposition whereupon the case is moved relative to a mold means whichaligns the plates of the battery within the case for subsequentprocessing. The comb and back dams of the mold means are then movedrelative to each other to form molding channels around the rows ofpositive and negative plate lugs of the stacks within the battery case.Preferably, the channels formed by the molds have a unique tapered shapesuch that the depth of each channel is greatest at the point adjacentthe intercell connection to be formed between adjacent battery cells.This shape adds structural integrity to the channels and providesgreater electrical conductivity at the point of intercell connectionwhere the current flow is greatest. During the aforementioned processingsteps, a continuously circulating lead delivery system has establishedan equilibrium temperature within a novel ladle means which is normallyclosed to the atmosphere to prevent oxidation of the molten lead. Oncethe molding channels have been established, the ladle is activated, atwhich time circulation of the lead is momentarily interrupted and thatportion of the lead stream which is isolated within the ladle is thendivided by the ladle into a plurality of preselected aliquots of moltenlead. Movement of the ladle from the standby to the casting positionfurther produces movement of the ladle spouts to the pouring position,whereupon the aforementioned aliquots of molten lead are simultaneouslydelivered into the molding channel in the appropriate amounts and withinthe desired temperature ranges to insure the formation of asubstantially homogeneous dross free integral strap-intercell connectorassembly. At the completion of this pouring cycle, the ladle isimmediately returned to the standby position to reestablish thecontinuous lead circulation therethrough and, following solidification,the comb and back dam portions of the apparatus are automaticallyretracted. The battery case is then withdrawn relative to the moldmeans, whereupon the cycle is complete and the apparatus is ready toreceive the next battery case for processing.

In FIG. 1, an embodiment of an apparatus for forming the battery strapsand intercell connections and molding the terminal post into the batterystraps is shown having a processing position over a work surface forreceiving the unprocessed battery case and stacks. Frame supports 2 and4 position the apparatus above the work surface designated generally 6.The remaining frame details consist of a closure pad support and housing12 running between frames 2 and 4; the surfaces of the frame are made upof side mounting plates 14 and 16 and top 18. The side and top surfacesare made out of conventional materials, such as sheet metal.

To faciliate movement of the batteries along the work surface,cylinderial rollers 8 are utilized, the axes of the rollers beingtransverse to the direction of movement of the batteries. A portion ofthe roller assembly is capable of movement in an upward direction drivenby an elevating means such as the cylinder 10 located beneath the worksurface. This acts to position the battery properly in elevation forporcessing by the apparatus.

Referring to FIG. 2, a cross-section of an open-topped battery casedesignated generally 119 is shown in position for processing. The bottomof the battery case 101 is shown resting on a series of rollers 8 of thework surface 6. Floor supports 103 of the battery support the innerfloor 105 of the battery on which the battery plates rest. Individualplate 120 is shown as one of many positive and negative plates presentin the battery. Each plate has an upwardly protruding portion called alug. The lug 124 of plate 120 and the lug 122 of the adjacent platebehind plate 120 are shown on opposite sides of the battery. The outercasing walls of the battery are indicated by 126 and 128. A cellularpartition of the battery which extends to the top of the battery case,is represented in FIGS. 2-4 as 121.

The entire battery 119 and a portion of the work surface below theapparatus upon which the battery rests are automatically elevated to aposition proximate to the mold dams of the apparatus by cylinder 10. InFIG. 2, the battery is shown in the elevated position with piston rod 11shown extended. In this embodiment the battery positioners 109 and 111attached to the apparatus align the battery in the work surface foroperation by the apparatus.

FIG. 2 also shows the molds in standby position above the battery. Twoof several back dam mold portions 104 and 106 are shown connected toback dam support members 108 and 110. The back dam support members 108and 110 are connected in any suitable manner to the mounting plates 14and 16. Two of several comb dam portions of the mold are designated 112and 114. The comb dams are also mounted to comb dam support members 116and 118.

Since the comb dams must move to engage the back dams, the comb damsupport members are mounted on a worm drive designated 20 in FIG. 1. Theworm drive turns in bushing supports 22 and 24 shown mounted to frame 2.A similar worm drive assembly exists attached to frame 4 but not shownin FIG. 1. To move the comb dams, air motor 26 is turned, which turnsshaft 28, and rotation of shaft 28 is converted into rotation of rods 30and 32 through dual bevel gear conversion box 34. Rotation of rod 30 isconverted into rotation of worm drive 20 through bevel gear conversionbox 36. Similarly, rotation of rod 32 will result in rotation of theremaining drive through bevel gear conversion box 38. Driving the motorin one direction will move the comb dams to engage the back dam portionsof the mold at which time the motor will stall, and driving of the motorin the other direction will serve to disengage the comb dams fromcontact with the back dams.

FIGS. 7 through 10 show details of a preferred embodiment of the damportions of the mold. In FIG. 10 a back dam 104 is shown. The back damis comprised of a substantially vertical member which is the upper blocksection 200. Holes 202 and 204 are used to support the vertical back damagainst the back dam support member. The lower region of the upper blockportion 200 is tapered along line 206 from break 207 to edge 208. Alsothe height of the upper block member 200 is tapered along the bottomedge 208 of the upper block member 200. The back dam is furthercomprised of a tapered section 210 lowermost in the back dam, saidtapered section forming a knife-like edge 212. The purpose of theknife-like edge 212 is for guiding the plates of the battery intoposition for the movement of said comb dams. The tapered section 210slides between the battery case wall 126 in FIG. 2 and the verticaledges 123 of the battery plates. This interposition of the back damtapered sections 210 and 211 between the battery casing walls 126 and128 and the vertical edges of the battery plates 123 and 125 aligns thelugs of the plates for subsequent processing. In the absence of batterypositioners 109 and 111, as in an alternate embodiment of thisinvention, the interposition of the back dams in the way just describedwill act to adjust the position of the battery on the work surface atthe same time.

In FIG. 9, an embodiment of a comb dam is illustrated. The comb dams aremoved across the tops of the battery plate surfaces to engage the backdams. The comb dam 114 is comprised of a vertical member 220 withsupport holes as in the back dam section designated 222 and 224. Thecomb dam further comprises a plurality of horizontal members 226 thatare parallel spaced apart. In the embodiment described herein thehorizontal members 226 intersect the vertical member 220 along a slopingline represented by 221 in FIG. 9. As a comb dam 114 moves across thebattery plates to engage a back dam 104, the horizontal members 226interpose themselves between the battery plate lugs, the plates slippingbetween the horizontal members in the grooves or slots 223. Once thecomb dam 114 has moved into position, a mold cavity is formed betweenthe vertical surfaces of the back dams and the comb dams and thehorizontal portions of the comb dams.

FIGS. 7 and 8, show two post comb dam embodiments which are similar tocomb dam 114 except for the depressions 228 in FIG. 7 and 230 in FIG. 8.When the molten lead is about to be poured into the mold section formedby the various dam members, the positive and negative terminal post ofthe battery are placed into these depressions 228 and 230 in the postcomb dams. A terminal post is shown in phantom in the depression 228 ofFIG. 7. Then as the molten lead is introduced into the mold andsolidifies, the terminal posts are molded into position in the strapassemblies.

Referring now to FIGS. 11 through 13, a ladle designated generally 132for casting a plurality of lead battery parts simultaneously is shown.In this preferred embodiment, the ladle comprises several parts. Themain body member of the ladle chamber is shown as a circular tube 300.Through the wall of the tube 300 there is placed a plurality of spacedapart holes which are delivery orifices 302, 304, 306, 308, 310, and312. A series of partitions 314, 316, 318, 320, and 322 are placestransverse to the axis of the tube between the delivery orifices andrunning partially across the cross-section of the tube 300. As in thisembodiment, the partitions 314 through 322 are held in place within thetube by insertion in slots which are places in the tubular wall. Thedelivery orifices open into a plurality of parallel spaced apart spouts324, 326, 328, 330, 332, and 334. One method of assembling the ladle isshown in FIG. 13. Two semicircular tubular members 336 and 338 are eachequipped with a plurality of lips attached adjoining the edges of themembers on either side. One set of lips 342 on member 338 have holestherethrough which align with threaded holes in the lips 340 on member336. Threaded bolts 334 can be placed through the holes in the lips 342and screwed into the threaded lips 340 on member 336 thereby forming theladle tube. The partial partitions 314 through 322 which are transverseto the axes of tubular member 336 are placed in slots in the walls oftubular member 336. These partitions extend across half of thecross-section of tubular 336. The spouts 324 through 334 are threaded atone end and screwed into threaded holes which exist in the walls of thetubular member 336. It can be seen from FIG. 13 that each of the spoutshas a tapered edge 346.

In the apparatus the ladle is rotatable between a standby position and apouring position. Please refer once again to FIG. 1, where the pistonrod (not shown) of cylinder 40 is shown attached to a coupler arm 42which engages the ends of drive members 44 and 46. Drive members 44 and46 are grooved on the outside surfaces so as to present a series ofparallel spaced apart teeth for engagement with circular drive members48 and 50 which are also grooved on their perimeters. The teeth on theperimeters of gers 48 and 50 are disposed to engage the truth on thelinear drive members 44 and 46. Connected to the ends of the ladles 132and 133 are rods, one of which is shown as 52 in FIG. 1. These rods areattached to either end of each of the ladles, the axis of the rods bengcoaxial with the axis of the ladles. The rods 52 engage gears 48 and 50forming a firm connection therebetween. Disposed intermediate the driverod and the end plates of the ladles are a washer 54, a biasing means orspring 56, another washer 58 and ladle support bracket 60 in FIG. 1. Ateach end of each ladle there exists a ladle support bracket such as 60which contains therein a groove 62 into which the rods 52 rest. Theseladle support plates not only provide a means for support for the ladlesbut also allow the ladles to rotate above the work surface. Hence whencylinder 40 is activated, the cylinder piston rod drives the coupler arm42 in a downward direction thereby moving the vertical drive members ina downward direction said drive members engaging the gears to rotate therods connected to the circular drive members. When the rods rotate, theyrotate the ladles.

The molten lead is delivered to the ladles, as shown in a schematic ofthe lead supply system is illustrated in FIG. 15. A reservoir designatedgenerally 500 contains molten lead which is pumped through supply linesdesignated 502 and 504 into the ladles 132 and 133 and out through thereturn line 506 and 508 back to the reservoir 500. The temperature ofthe molten lead in the reservoir can be controlled to insure that thelead remains molten throughout the system. In the standby position,molten lead flows through the ladle chamber 300 of FIG. 11 unimpededalong the inside surface portion designated 348. The spouts, as shown byspouts 334 and 335 in FIG. 2, are pressed against the closure pad 138.This insures that in the standby position while the molten lead iscirculating through the ladles no dross can form since no portion of thesystem is open to the atmosphere. As the ladle begins to rotate, thepartial partition 314 through 332 shown in FIGS. 11 and 12 divide themolten lead contained within the ladle into preselected aliquots. Forexample, the ladle shown in FIG. 11 has six spouts and six partitionedcompartments within the chamber for delivering measured portions ofmolten lead of each of the channels formed by the molds within each ofthe six cells in the battery. There are two such ladles in the apparatuslocated for pouring such portions of molten lead into the channelsformed around two rows of battery lugs. When the ladle has rotatedsufficiently far so tht the molten lead now covers over the deliveryorifices 302 through 312, the molten lead will then begin to pour fromthe ladle through the spouts 324 through 334.

In FIG. 14a, the ladle is illustrated in the standby position with thespout 324 pressed against the closure pad 138 along the tapered edge 346of the spout. The dashed line 402 in FIG. 14a, shows the level of moltenlead as it flows through the the ladle in the standby position. Themolten lead enters into the ladle chamber through the opening 404 in theladle support plate 60 shown as the solid circle in FIGS. 14a-d and thehole 406 in the ladle end shown as a dotted circle in FIGS. 14a-d. Acorresponding pair of holes exists in the opposite end of the ladle andladle support plate. A supply line is connected to the opening 404 inwhich molten lead is introduced into the ladle chamber. As the ladlebegins to rotate, as in FIG. 14b, the spout 324 leaves the closure pad138 and the opening 406 in the end of the ladle chamber moves away fromthe opening 404 in the ladle support plate 60 describing a circular pathand thereby cutting off the supply of molten lead to the inside of theladle. The phantom lines 408 in FIGS. 14a-d, represents the rotation ofthe partitions 314-322. In FIG. 14c, the partition has intercepted thelevel of molten lead residing in the chamber thereby beginning to dividethe puddle of molten lead within the ladle into sections for pouring. Bythe time the spout has rotated around as shown in FIG. 14d, the moltenlead has been segmented into the various compartments within the ladleand the lead begins to pour from the ladle through the deliveringorifices 302-312 and spouts 324 through 334 into each of the channelsformed by the molds in the battery.

FIGS. 2 through 6, show the positions of the various components of theapparatus at different stages during the casting process. FIG. 2 showsthe apparatus in a standby position with the battery in place. The combdam portion designated generally 112 and 114 have not yet begun to moveand interpose themselves among the battery plates and engage the backdam sections designated generally 104 and 106. The ladle membersdesignated generally 130 and 132 have not yet begun to rotate and spouts334 and 335 are still pressed against closure pad 138.

In FIG. 3, the comb dam portions of the mold have engaged the back camsand interposed themselves among the battery plates. The ladle spoutshave not yet begun to rotate.

Two adjacent cells in the battery are shown in FIG. 4 formed by thepartitions 150, 156, and 158. The spaces within each cell communicatewith one another through the aperture 152 in partition 150. The plates154 which form the stacks in each of the cells are shown as viewed fromthe edge of the plates. The lugs of alternate plates are labeled 124 andare shown interposed with the horizontal portions 226 of the comb dam.The upper surfaces of the horizontal portions 226 of the comb dam in thecell formed by partitions 156 and 150 slopes generally downward fromleft to right while the upper surfaces of the horizontal portions of thecomb dam in the cell formed by partitions 158 and 150 slopes generallydownward from right to left.

In FIG. 5, the molds are formed as in FIG. 3 and the ladles have rotatedinto the pour position. The inside surfaces 201 and 203 shown in FIG. 10of back dams 104, the inside surface of vertical member 220 of comb dam114, the top surfaces of the horizontal portions 226 of comb dams 114,the plate lugs interposed in grooves 223 of FIG. 10, and the sidesurfaces of the battery partitions 156 and 150 have come together toform the surfaces of a single mold channel. Two such channels are shownin FIG. 6 connected through the opening 152 in partition 150. The tips225 of the horizontal members of the comb dam slip under the edge 208 ofthe back dam thereby forming a seal between the comb dam and the backdam along a sloping or tapered intersection. It will be seen that theslope 221 of the horizontal members of a comb dam mate with a slope 208of the corresponding back dam forming this seal.

FIG. 6 is a view along the lines and arrows 4--4 in FIG. 5 showing across-section of the strap and intercell connection 160. The molten leadwas introduced into the adjacent channels formed by the molds by two ofthe spouts of one of the ladles. The molten lead flows together throughthe intercell opening 152 in partition 150 and forms a single casting160. The depth of the casting is greatest at the intercell connectionand tapers to a shorter depth at either end of the casting near thepartitions 156 and 158. This greater mass of metal at the intercellconnection lowers the electrical internal resistance of the battery byproviding a greater mass of metal at the point of highest current flowin the battery. This greater depth of the casting throughout a portionof the casting length from partition 156 to partition 158 adds to thestructural integrity of the overall strap configuration in the battery.

Referring again to FIG. 5, the spouts 334 and 335 have rotated aroundand the tapered edge of the spouts enters into the top opening of thechannel formed by the vertical members of the back dam and comb dam. Thelong vertical lengths of the channels formed by the back dam and combdam portions of the mold and the long spout connected to the ladleprovide a sure path for the molten lead to follow in leaving the ladleand entering the mold thereby insuring that all of the molten lead willenter the desired channel within the battery and splashing of the moltenlead will be minimized. By simultaneously introducing molten lead intoeach individual channel formed within the battery in the way justdescribed, a homogeneous strap is formed and reliable intercellconnections are cast. FIGS. 5 and 6 show that the battery lugs have beenmelted down as a result of being immersed in the molten lead. Thetemperature of the molten lead introduced into the channels required tomelt and mix with the lead of the lugs can be controlled by controllingthe temperature of the molten lead in the reservoir.

The partitions, which are present in the battery separating the stacksin the battery cells, already have apertures punched in them, saidapertures shown by the dotted circle 152 within the rows of battery lugsin FIGS. 2 and 3, and said apertures being far enough below the top ofthe partitions to be beneath the electrolyte level when electrolyte isintroduced into the battery later on in the battery assembly process.The back dam portions and comb dam portions of the mold which arepresent in each partition of the battery, cooperate with the partitionto form seals. The horizontal portions 226 of the comb dam members arebelow the partition apertures 152 so that when molten lead issimultaneously introduced into mold channels on either side of apartition, molten lead will flow through the aperture thereby forming anintercell connection. See FIG. 6. These intercell connections are madebeneath electrolyte level thereby preventing undue hazard due to sparksand the action of the molten lead as it solidifies tends to create anexcellent seal for the intercell connection. This method of forming thestraps and intercell connections gives the shortest possible electricalpath; minimizes internal electrical resistance; requires the minimumamount of lead, works equally well in poly or rubber battery cases; andeliminates the burning operation on groups or the necessity of cast onequipment when forming battery straps and intercell connections.

It will be understood that various changes in the details, materials andarrangement of parts which have been herein described and illustrated inorder to explain the nature of this invention, may be made by thoseskilled in the art within the principle and scope of the invention asexpressed in the following claims.

It will further be understood that the "Abstract of the Disclosure" setforth above is intended to provide a nonlegal technical statement of thecontents of the disclosure in compliance with the Rules of Practice ofthe United States Patent and Trademark Office, and is not intended tolimit the scope of the invention described and claimed herein.

What is claimed is:
 1. An apparatus for automatically casting the strapsand intercell connections of a lead-acid storage battery containing abattery case and a plurality of cellular partitions, comprising:(a) worksurface having a processing position thereon for receiving open topbattery cases having a plurality of stacks of positive and negativeplates in the cells thereof, said plates each having protruding lugsformed thereon; (b) mold means located at said processing position forselectively defining molding channels around rows of positive andnegative lugs of said stacks within said case, said mold meanscomprising a plurality of dams for forming the surfaces of a mold withat lest one dam movable in relation to the remaining dams; (c)translating means connected to said mold means for moving the movabledam portion of the mold; (d) casting means associated with said moldmeans at said processing position movable between a standby position forallowing molten lead to circulate therethrough and a pouring positionfor simultaneously introducing molten lead into said molding channel tocast the straps and intercell connections of said battery; (e) rotatingmeans connected to said casting means for selectively moving saidcasting means between said standby position and said pouring position;(f) at least one molten lead supply means connected to said castingmeans for supplying molten lead to said casting means; and (g) at leastone molten lead return means connected to said casting means forreceiving and returning uncast molten lead from said casting means to atleast a portion of said supply means.
 2. An apparatus for automaticallycasting the straps and intercell connections of a lead-acid storagebattery comprising a battery case having at least six cell compartmentstherein defined by at least four intercellular partitions, saidapparatus comprising:(a) a work surface having a processing positionthereon for receiving open topped battery cases having a plurality ofstacks of positive and negative plates in the cells thereof said plateseach having protruding lugs formed thereon; (b) mold means located atsaid processing position for selectively defining at least six moldingchannels around the rows of positive and negative lugs of said stackswithin said case; (c) casting means associated with said mold means atsaid processing position, movable between a standby position forallowing molten lead to circulate therethrough and a pouring positionfor simultaneously introducing molten lead into each of said at leastsix mold channels to cast the straps and intercell connections of saidbattery, said casting means comprising no more than two ladle means fordividing said molten lead to be simultaneously introduced into aliquotsof preselected volumes as said casting means is moved from said standbyposition into said pouring position; (d) at least one molten lead supplymeans connected to said casting means for supplying molten lead to saidcasting means; and (e) at least one molten lead return means connectedto said casting means for receiving and returning uncast molten leadfrom said casting means to at least a portion of said supply means,whereby movement of said casting means between said standby and saidpouring positions will simultaneously cast the straps and intercellconnections of said battery.